U.S. patent application number 10/008908 was filed with the patent office on 2003-03-20 for printer compact coil winding system.
Invention is credited to Barrus, Gordon B., Kinley, John Stanley.
Application Number | 20030051616 10/008908 |
Document ID | / |
Family ID | 26678777 |
Filed Date | 2003-03-20 |
United States Patent
Application |
20030051616 |
Kind Code |
A1 |
Kinley, John Stanley ; et
al. |
March 20, 2003 |
Printer compact coil winding system
Abstract
An impact printer having one or multiple lines of hammers on a
hammerbank for impacting a print ribbon against a print media after
release by one or more electrically energized coils in a magnetic
circuit with one or more pole pieces retaining the hammers prior to
impact. One or more of the coils has a spaced winding thereby
allowing filling of the spaced winding during return winding.
Another embodiment utilizes a longitudinal return from an initial
winding which can be formed with multiple layers or multiple
overlappings of the longitudinal return. The foregoing minimizes a
first dimension while having controlled wire crossing resulting in
expansion in a second dimension, thereby allowing compaction of
magnetic circuits in the first dimension.
Inventors: |
Kinley, John Stanley; (Costa
Mesa, CA) ; Barrus, Gordon B.; (San Juan Capistrano,
CA) |
Correspondence
Address: |
George F. Bethel
Beehler & Bethel
Suite 230
180 Newport Center Drive
Newport Beach
CA
92660-6972
US
|
Family ID: |
26678777 |
Appl. No.: |
10/008908 |
Filed: |
December 6, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60323458 |
Sep 18, 2001 |
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Current U.S.
Class: |
101/93.48 ;
400/124.01 |
Current CPC
Class: |
B41J 2/22 20130101 |
Class at
Publication: |
101/93.48 ;
400/124.01 |
International
Class: |
B41J 002/22 |
Claims
1. A line printer comprising: a plurality of hammers on a
hammerbank with tips for printing; at least one permanent magnet
for retaining said hammers; a pole piece magnetically linked to
said permanent magnet; and, a coil wrapped around said pole piece
having a wire winding extending around said pole piece in a first
direction and returning across said winding in the other
direction.
2. The line printer as claimed in claim 1 further comprising: said
wire returning across said winding in the first direction
longitudinally of said pole piece extends along a width portion
which is narrower than the breadth.
3. The line printer as claimed in claim 2 wherein: the width of
said coils is in the direction of the longitudinal orientation of
the hammerbank; and, the breadth of said coils is orthogonal to the
width.
4. The line printer as claimed in claim 1 further comprising: said
coils having at least one winding extending in two directions.
5. The line printer as claimed in claim 2 further comprising: a
winding overlying said wire forming said longitudinally returning
wire.
6. A line printer having a plurality of hammers in a hammerbank
which are retained by a permanent magnet until release comprising:
a pole piece magnetically coupled to each hammer; and, a coil
wrapped around said pole piece having a width in the longitudinal
direction of said hammerbank less than the breadth.
7. The line printer as claimed in claim 6 further comprising: said
coil has its breadth increased by an angular crossing of a wire
over an underlying coil winding.
8. The line printer as claimed in claim 7 further comprising: said
angular crossing wire extends longitudinally along said pole
piece.
9. The line printer as claimed in claim 7 wherein: said angularly
crossing wire crosses over a previous winding having a space
between each winding.
10. The line printer as claimed in claim 9 wherein: the space
between each winding is at least two or more pitches with at least
one winding filling in the space.
11. The line printer as claimed in claim 6 further comprising: a
pair of hammerbanks each having a row of hammers; and, said coil
has an angular crossing across the width distal from an adjacent
coil.
12. The line printer as claimed in claim 11 further comprising:
each pole piece having two portions wrapped with a coil, the coils
of which have an angular crossing removed from the space between
each portion.
13. A line printer coil wrapped around a pole piece comprising: a
coil having a width orthogonal to the longitudinal direction of
said pole piece; and, a breadth orthogonal to the width, said
breadth being greater than said width.
14. The line printer as claimed in claim 13 further comprising:
said breadth is increased with respect to said width by an angular
portion extending over and crossing a previous winding.
15. The line printer as claimed in claim 14 wherein: said angular
portion extends longitudinally in the direction of said pole piece
over a previous winding.
16. The line printer as claimed in claim 14 wherein: said angular
portion is a longitudinal return of a previous winding.
17. An impact printer comprising: at least one line of hammers on a
hammerbank having printing tips on each hammer; a print ribbon for
impact by said tips against a media to be printed upon; at least
one magnet for magnetically retaining said hammers prior to
impacting said ribbon; a pole piece magnetically linking said
magnet for retention of one of said hammers; and, a coil
electrically connected for releasing one of said hammers, having a
winding of wire with a space of at least one wire filled in with a
second winding.
18. The impact printer as claimed in claim 17 further comprising:
said winding of wire filling in said spaces crosses over said
spaced winding across the width so that the breadth is increased
with respect to the width.
19. The impact printer as claimed in claim 18 wherein: said spaced
winding is wound on said coil after a plurality of non-spaced
windings.
20. The impact printer as claimed in claim 19 wherein: said spaced
winding has three pitches and is filled with one winding.
21. The impact printer as claimed in claim 19 wherein: said spaced
winding has two pitches and is filled in with one winding.
22. The impact printer as claimed in claim 18 further comprising:
two rows of hammers on a hammerbank; and, wherein said coils are
placed in a proximal and distal relationship with respect to each
of the rows of hammers.
23. The impact printer as claimed in claim 22 wherein: each of said
distal coils has a spaced winding and said proximal coils are wound
without any spacing.
24. A line printer comprising: a bank of hammers with printing tips
mounted on a hammerbank; a permanent magnet for retaining said
hammers; a pole piece magnetically coupled between said magnet and
one of said hammers; and, a coil around said pole piece having a
spaced winding with a second winding at least partially filling the
space.
25. The line printer as claimed in claim 24 further comprising:
said spaced winding is wound with odd numbered pitches with one of
said second windings at least partially filling in between said
spaced windings.
26. The line printer as claimed in claim 24 further comprising:
said spaced winding is wound with even numbered pitches with said
second winding at least partially filling in said spaced
windings.
27. The line printer as claimed in claim 24 wherein: said pole
pieces comprise two portions with a bobbin surrounding each of said
portions; a coil wrapped around each of said bobbins; and, said
coils formed with said spaced winding are wound so as to increase
the breadth of said coil with respect to the width.
28. The line printer as claimed in claim 27 wherein: said bobbins
are formed as pairs on a bobbin frame member that encompasses a
portion of said pole pieces.
29. The line printer as claimed in claim 24 wherein: said winding
filling said spaced windings terminates at a terminal connection
distal from said pole piece ends that are proximate to said
hammers.
30. A line printer comprising: a first and second bank of printing
hammers, each bank having at least one pole piece magnetically
coupled to a permanent magnet with an end extending in proximity to
a hammer; and, a coil wound around each of said pole pieces having
a breadth of said coil larger than the width.
31. The line printer as claimed in claim 30 further comprising:
said coils have a width orthogonal to the axis of said pole piece
and a breadth orthogonal to the width.
32. The line printer as claimed in claim 31 further comprising:
said pole pieces each have two portions with windings; and, said
coils in part comprising distal coils from an adjacent pole piece
having a winding crossing over a former winding along the width of
said coils distal from an interface with proximal coils of said
adjacent pole pieces.
33. Line printer coils for a line printer having two banks of print
hammers in alignment with each other each bank of print hammers
having two pole piece ends in juxtaposition to a hammer on said
bank comprising: a first pair of coils, each wrapped around a pole
piece and forming a distal and a proximal coil; a second pair of
coils, each wrapped around a pole piece forming a distal and
proximal coil; and, said distal coils being wound in one direction
with at least one return of wire along the width of the coil
removed from the space between said proximal and distal coils.
34. The line printer coils as claimed in claim 33 further
comprising: said coils having a width as measured across said coils
in general alignment with the hammerbank and a breadth orthogonal
to said width, said width being a lesser dimension than said
breadth.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The field of this invention lies within the impact printer
art. More particularly, it lies in the art of releasing a hammer
with a pin to strike a ribbon for impacting a given media upon
which printing is to take place. The field more specifically
devolves down to the field of providing an efficient release of
impact printer hammers from permanent magnetic retention and the
provision of electromagnetic coils to overcome permanent magnetic
retention. The invention is enhanced by a coil winding system which
maximizes the efficiency of the printer and the aspects of line
printing.
[0003] 2. Description of the Prior Art
[0004] The prior art with respect to impact printers relies upon
the impacting of a ribbon with a hammer having a tip on it. The tip
specifically impacts the print ribbon and places a dot on a media
to be printed upon.
[0005] The printing takes place in a manner so that a dot matrix
characterization of alpha numeric, bar code and other printing can
take place. This particular type of printing is effected oftentimes
by high speed line printers.
[0006] Line printers generally have a hammerbank with a plurality
of hammers. The hammers are lined up to print in a bank or line of
dots across a specific media moving past the hammer tips. The
hammers with the tips are usually retained by a permanent magnet
which draws them into a secured location of magnetic retention. The
magnetic retention is overcome by electromagnetic coils. These
electromagnetic coils are generally wrapped around a pole piece
which couples the permanent magnetism.
[0007] It has been found that the greater number of windings on a
pole piece for permanent magnetic release effects greater
efficiency. This is due to the fact that in order to minimize
power, an increase of the number of turns and/or the lowering of
resistance is desirable. The general formulation of current squared
times resistance equals power is enhanced by the fact that the flux
of the electromagnetic coils when combined with the equation of
power creates a result wherein the larger number of turns results
in lower power requirements. In effect, if greater turns of wire in
the same space or through geometrically improved overlapped layers
can be utilized by the electromagnets for overcoming the permanent
magnetism on the pole pieces, the relative power is reduced. Also,
when reductions in power are encountered, more facile and discrete
printing can take place.
[0008] Recently, it has been common to have hammerbanks and line
printers formed as dual rows, banks, or lines of hammers and tips.
This is based upon an upper row or line of hammers and a lower row
or line of hammers. One row or line of hammers prints one
particular line while the other set prints another line. In this
manner, multiple or dual line printing can take place
simultaneously with the placement of the hammerbank in a specific
location regarding the media to be printed upon.
[0009] When utilizing dual rows of hammers, it is preferable to
reduce the gaps or spaces between the hammers if possible and/or
maximize the number of coil turns to reduce power concurrent with
the largest thickness of wire to lower resistance. The geometry of
such winding on the pole pieces is such wherein there is a
difficulty created due to their compact nature. Further to this
extent, the electromagnetic coils of the pole pieces are generally
magnetically in series. An upper and lower portion of the pole
pieces are wound with a series winding, making the compaction
problem more acute.
[0010] In order to enhance the ability to make compact coils wound
around the pole pieces, the applicant's invention utilizes a
winding system to maximize the placement of wire on a pole piece in
one dimension while eliminating enlargement in another dimension.
This diminishes the spacing between pole pieces.
[0011] The breadth of the pole piece is utilized to place the
excess winding that is desired to avoid increasing the overall
width of the pole piece winding. Since width relates to the
placement of adjacent or side by side coils, the width dimension
becomes somewhat controlling as to compaction of adjacent coils.
When considering the maximum winding as to its proximity to another
coil, this inventive winding effects an enhanced orientation for
closer more compact coil relationships.
[0012] Previously, it was difficult to provide an odd number of
layers of wire on a coil bobbin such that the leads started and
finished at the same end of the coil bobbin. Instead, the winding
started and finished at opposite ends of the coil bobbin. This
particular limitation reduced the possible coil turns and
combinations when in a confined space. If there wasn't enough room
for six layers the extent of the winding would have to be limited
to four layers. This invention allows a fifth layer, or other odd
number of layers or coil combinations.
[0013] This invention overcomes the deficiencies of the prior art
by winding layers that increase the pitch or spacing for winding
another pitch or more located between the increased spacing. The
greater pitch is spaced to place one third, one half or more of the
number of turns between the windings. The wire is pitched back down
to the starting position netting the equivalent of an additional
layer or portion thereof as the case may be. The crossings increase
the breadth but not the width.
[0014] A further embodiment incorporates a first winding in one
direction and a longitudinal return along the coil. Another winding
then overlies the longitudinal return. This increases the breadth
of the coil without increasing the width in an undesirable manner.
The result is to allow coils having increased winding in closer
proximity.
[0015] With the foregoing systematic approach of winding coils,
this invention finds great utilization in the winding of line
printer coils.
SUMMARY OF THE INVENTION
[0016] In summation, this invention utilizes a compact wire winding
system for adjacent coils by winding layers of wire in multiple
pitches or spacing of the wire to place a lesser number of turns on
a winding in one direction and then increasing the turns back to
the starting point which nets the equivalent of an extra, or
portion of an extra layer. The winding can also provide for a
directional winding with a longitudinal return which increases a
less critical dimension such as the breadth of the coil rather than
the width in order to diminish spacing between the widths of
coils.
[0017] More specifically, the invention utilizes a spacing of the
turns in a given direction winding. The spacing relates to the
pitch in even or multiple spaces or other such gaps depending upon
the winding desired. This allows for the wire to be then fed into
the gaps in the winding going in the other direction while
providing for crossovers in the less critical dimension of the
breadth.
[0018] The crossing of the windings can also be enhanced by a
winding outwardly that has the turns crossed by a longitudinal
return overlying the windings. The direction of the return is
directionally along the axis of the pole pieces.
[0019] The crossing of the turns and wires occur at locations that
are not critical dimensions occurring at the coil breadth
dimensions. This is particularly important when coil width control
and dimensions are required to be maintained in the most compact
manner. The feed of the wire on the return can be with a crossover
arrangement in multiple arrangements to be expanded on hereinafter
in multiple embodiments.
[0020] The invention utilizes a wire payout needle which winds the
wire around the pole pieces and bobbin frame by movement in a
rotational manner or in some cases the needle itself in a
rotational manner around the pole pieces and bobbin frame.
[0021] Feeding of the needle relatively inwardly and outwardly also
enhances movement of the overall winding creates the spacing,
pitch, or longitudinal crossing of the wire back to the beginning
of the wind.
[0022] A group of jaws and holding fixtures can be utilized with a
program for winding the bobbins around the pole pieces to effect a
specific winding configuration that is desired. This winding
configuration can be programmed for any particular type of winding
that is desired in order to net the compact relationship of the
invention and the system for winding.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 shows a perspective view of a portion of a line
printer utilizing this invention.
[0024] FIG. 2 shows a fragmented perspective view of a hammerbank
with the cover partially broken away.
[0025] FIG. 3 shows a sectional view of a three pitch winding
scheme for the bobbins and coils of this invention as sectioned
along lines 3-3 of FIG. 1.
[0026] FIG. 4 shows a detailed perspective view of the windings as
shown in FIG. 3.
[0027] FIG. 5 shows a sectional view of the windings on a frame
with two bobbins showing a three pitch orientation with the ability
to fill in between the wires with two extra wires for enhanced
winding compaction.
[0028] FIG. 5A shows a similar view to FIG. 5 with an alternative
embodiment.
[0029] FIG. 6 shows a side elevation view of the bobbin on the pole
piece being wound.
[0030] FIG. 7 shows a last winding being effected on the pole piece
after the fourth or even layer thereof.
[0031] FIG. 8 shows a fully wound bobbin with a second bobbin being
wound.
[0032] FIG. 9 shows the winding completed on four windings or even
numbered windings on the second bobbin wound.
[0033] FIG. 10 shows the needle winding a three pitch winding
wherein the winding is skipping to allow insertion of up to two
wires between the winding.
[0034] FIG. 11 shows the completion of the winding with the needle
prepared to initiate winding and filling of the spaces between the
three pitch winding.
[0035] FIG. 12 shows the needle moving in proximate relationship
across the wound winding to effect the windings into the spaces
therebetween.
[0036] FIG. 13 shows a view in the direction of lines 13-13 of FIG.
12 with the needle moving and describing the winding of the coils
and the extra layers between the gaps of the three pitch
windings.
[0037] FIG. 14 shows the last of the coil being wound with the
spaces being filled.
[0038] FIG. 15 shows a two pitch winding orientation with a detail
of the hammerbank as sectioned through the hammerbank.
[0039] FIG. 16 shows an alternative embodiment of this invention
with a fragmented side elevation of the bobbin being wound.
[0040] FIG. 17 shows the opposite side of that shown in FIG.
16.
[0041] FIG. 18 shows the winding being made with the longitudinal
relationship of the return wire from an end view of that shown in
FIG. 17 along lines 17-17.
[0042] FIG. 19 shows a second winding being applied to the
bobbin.
[0043] FIG. 20 shows a return of the wire longitudinally in the
direction of the bobbin.
[0044] FIG. 21 shows the feed of the wire from one bobbin being fed
to another.
[0045] FIG. 22 is a sectional view of the winding of the wire in
the direction of lines 22-22 of FIG. 20.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] Looking at FIG. 1 it can be seen for purposes of explanation
that the showing of a line printer is set forth in a perspective
view. In particular, the line printer having a base 10 is shown
that can be mounted on a console or a portable movable base having
a frame 12 supporting the remaining portion of the line printer. In
this particular case, the line printer is shown having a left hub
14, and a right hub 16, on which spools 18 and 20 are mounted.
These two respective spools 18 and 20 are wound with a print ribbon
22.
[0047] The particular showing of FIG. 1 shows the spool 18 being
emplaced on the hub 14 with the spool 20 already mounted on hub
16.
[0048] The print ribbon 22 moves backwardly and forwardly in a
transversal across the line printer hammers. This allows the ribbon
to be impacted and emplace a dot matrix configuration on the media
that is being printed.
[0049] The media is paper in a fanfold configuration being driven
by a tractor on either side namely tractors 28 and 30 that move the
paper across the throat of the printer.
[0050] The tractor units are driven by a splined rod 32 and can be
adjusted along the length of a support rod 34.
[0051] The media such as the paper can have a plurality of punched
out portions driven by the tractors 28 and 20. The paper can be
advanced by a knob 38 moving the splined rotating rod 32 in order
to advance the media.
[0052] FIG. 2 shows a fragmented portion of a hammerbank 40. The
hammerbank comprises a plurality of hammers 42 in an upper bank or
line and hammers 44 in a lower bank or line. These respective
hammers 42 and 44 have tips or pins 46 and 48 projecting therefrom
in order to provide for the dot matrix printing of this invention.
When the print ribbon 22 passes thereover, it is impacted by the
tips 46 and 48 in order to place a dot or plurality of dots on the
media.
[0053] The hammerbank has a cover 50 with a plurality of openings
52 for receipt of the upper pins or tips 46 and openings 54 for
receipt of the lower pins or tips 48. The cover 50 is incorporated
with a mask assembly in order to mask the ribbon from the
media.
[0054] Cover alignment pins such as pin 56 is utilized for holding
the cover 50 in its respective location for proper orientation of
the cover on the hammerbank.
[0055] Each of the upper hammers 42 and lower hammers 44 forming a
line are supported and formed on frets 60 and 62. These frets 60
and 62 can comprise a multitude of hammers. Such frets 60 and 62
are generally machined or cut by electro-discharge milling from a
single piece of metal so as to provide the hammers in the
particular format as shown. The tips 46 and 48 are then formed or
welded, braised or connected in any suitable manner to the hammers
42 and 44.
[0056] The frets 60 and 62 are secured to the hammerbank by means
of securements 64 and 66 which can be threaded attachments such as
screws, nuts or bolts, etc.
[0057] The hammerbank 40 is formed as a machined element from a
casting in any suitable manner to provide a slot 68. The slot 68
receives a circuit board 70 which can have the logic, power, and
drive for the hammers. The circuit board 70 can be connected to the
controller or another portion of the printer by means of a flex
cable or other suitable means.
[0058] Looking more specifically at FIG. 3 which has been sectioned
along lines 3-3 of FIG. 1 it can be seen that the hammerbank 40 is
shown in greater detail with the coils and pole pieces as detailed
hereinafter. In particular, the hammerbank 40 is shown with the
frets 60 and 62 and their respective hammers 42 and 44. Also, the
tips 46 and 48 of the hammers are shown for striking the ribbon 22
which passes thereover. The cover 50 is also shown mounted
thereon.
[0059] The hammerbank 40 has electrical components on the circuit
board 70 with connectors 80 and 82 for the upper hammerbank portion
and connectors 84 and 86 for the lower hammerbank portion.
[0060] A bobbin and frame configuration or assembly 88 for the
upper assembly of hammers is shown. A like bobbin and frame
configuration or assembly 90 is also shown. These frame or bobbin
configurations are split along their axial portion and receive pole
pieces 92 and 94 for the upper set of hammers and 96 and 98 for the
lower set of hammers.
[0061] These respective pole pieces are made of magnetically
conductive metal and receive permanent magnets 100 and 102
respectively in the upper and lower pole pieces. The pole pieces
can be laminated as shown to reduce eddy currents they can also be
solid pole pieces. The ability to use solid pole pieces is enhanced
by this invention because although the eddy currents might
increase, the power saved diminishes the effect due to eddy current
losses. These respective magnets 100 and 102 magnetically retain
the hammers 40 and 42 against the pole pieces 92, 94, 96, and 98
until released by electromagnetic power overcoming the permanent
magnets 100 and 102.
[0062] The electromagnetic force in order to overcome the retentive
magnetism of the magnets 100 is provided through an upper distal
coil 110 and an upper proximal coil 112. In like manner a lower
distal coil 114 and a lower proximal coil 116 are utilized to
overcome the magnetism of the respective magnet 102.
[0063] One of the main reasons for this invention is to allow for
compact winding of the coils 110 through 116 with respect to their
width and breadth. The breadth being shown as the dimension seen in
FIG. 3 and the width being orthogonal thereto. These dimensional
relationships will be defined more fully in FIG. 4.
[0064] With increased windings, less power is utilized with respect
to given wire diameter. The power is decreased or minimized by
increasing the number of turns or lowering resistance. In effect,
when increasing the number of turns or lowering the resistance,
less power is required for the electromagnetic magnetism to reverse
the permanent magnetism of the magnets 100 and 102. In this manner
less power is lost to heating. Thus, one of the major reasons for
this invention is the ability to apply extra turns to bobbins and
frame members 88 and 90 in close proximity to each other as to
their width and the respective proximal and distal coil
spacings.
[0065] Looking more particularly at FIG. 4, the details of the
coils 110 through 116 and the bobbin and frames members 88 and 90
can be seen. FIG. 4 shows the bobbins and frame members 88 and 90
with the respective coils 110 through 116. These respective coils
110 through 116 have been wound on the frames and bobbins 88 and
90. Although showing laminated pole pieces in FIG. 4, it should be
understood that this invention enhances the ability to use solid or
non-laminated pole pieces as well.
[0066] The frames and bobbins 88 and 90 are formed in a bifurcated
manner in a split along line 122. These splits or parting lines 122
allow the frame and bobbin members 88 and 90 to be joined together
and hold the respective pole pieces shown as pole pieces formed of
laminated metal members. The pole piece eddy currents are reduced
by the lamination of pole pieces 92, 94, 96, and 98. Nevertheless
the reduction in power due to this invention allows the use of
solid or non-laminated pole pieces even though a certain amount of
power might be lost through eddy currents.
[0067] The pole pieces 92, 94, 96, and 98 can be stamped or milled
terminating in the ends of the pole pieces adjacent the hammers 40
and 42, shown as extensions of the pole pieces 92, 94, 96, and 98.
When formed this way, a slot 401 and 403 is provided that receive
the magnets 100 and 102 respectively. Also, as can be seen
connectors 80, 82, 84, and 86 are shown having extensions passing
therefrom which provide for the connection of the circuit board 70
and its drivers to the coils 110 through 116.
[0068] Each set of coils 110 and 112, and set 114 and 116 are wound
on a bobbin or frame such as frame 88 or 90. The distal coils and
the proximal coils are wound in series. This can be seen as the
series winding starting at the wire connection or terminal 130 and
terminating in the wire terminal connection 132. However, the
windings could also be in parallel rather than in series.
[0069] The wire wound around the respective distal and proximal
coils 110 and 112 is in series starting at wire connection or
terminal 130 and terminating at wire or terminal connection 132.
The windings in some cases, as previously stated, can also be such
where they are electrically in parallel.
[0070] The initial wire connection starting at the connecting point
130 traverses a slot 134 on the bobbin or frame 88. The slot 134
allows the wire to be wound around the bobbin in the manner to be
described. Thereafter, the wire returns to the connection point 132
in the return slot 135. This is also true of the distal and
proximal coils 114 and 116 except in a reverse manner.
[0071] The width (W) and the breadth (B) respectively of the coils
when spoken herein refers to the following. The width (W) of the
coil is measured across the distance shown as width W of FIG. 4.
The breadth (B) of the coil is shown as the breadth B in FIG. 4.
The breadth and the width of the coils are orthogonal to each
other.
[0072] As can be seen from FIG. 4, the width W of the coils when
packed together in their multi-coil function provides for a very
tight and compact relationship. Also, the proximal and distal coil
combination must be accounted for with regard to the breadth B of
the coil due to the number of windings. This invention enhances the
ability to increase greater breadth B of the coils such as the
distal coils 110 and 114 due to the winding thereof while at the
same time enhancing the narrowness of the width W.
[0073] A first description of the invention in FIGS. 1 through 15
is directed toward the crossover, skipped pitch concept. The one
hereinafter is directed to a single wire return after each winding
in FIGS. 16 through 22 so as to place the return on the outer
portion of the coil. This limits the width while increasing the
breadth in a non-critical location by one wire upon each
return.
[0074] In reference to FIGS. 3 and 4, the windings of the coils are
shown as four windings on the proximal coils 112 and 116 and five
windings on the distal coils 110 and 114. These respective windings
are such wherein the windings on the proximal coils 110 and 116 are
tightly wound onto each other without any spacing, and in a single
pitch orientation. In effect they are wound with a single pitch
without any gaps as the windings are laid down. The distal coils
110 and 114 are wound so as to provide for four windings initially
with a fifth winding incorporating a staggering, spacing, or pitch
of three wires which are filled in with a reverse traversing of the
bobbin.
[0075] The last winding starts out on the distal coils 110 and 114
by skipping a second and third pitch in each case and filling in
with one or more wire windings thereafter. Thus, winding
orientation or pitch, depending upon the number of windings skipped
in the next to last windings can effectively provide for variable
dimensions as to width W and breadth B of the coils for enhanced
packing of the coils in a tightened configuration as seen in FIG.
4.
[0076] Another consideration is that the terminal points of the
windings should terminate towards the rear of the coils or
proximate the wire connections 130 and 132. For a winding to be
effective it should not terminate at the forward end or closest to
the ends of the pole pieces proximate the hammers 40 and 42. If so,
the wire must be run backwardly in another path to its respective
wire connection 132 or a like connection.
[0077] Looking more particularly at FIG. 5 which shows the bobbin
and frame 88, it can be seen that the pole pieces extend outwardly.
The upper pole piece 92 magnetically returns through the lower pole
piece 94. This is true as to the permanent magnetism with the
hammer 42 serving as the magnetic bridge. The bobbin itself formed
on the frame and bobbin member 88 is shown as a plastic bobbin
member 150 on the upper portion and 152 on the lower portion which
wrap around the magnetically conductive pole pieces 92 and 94.
[0078] The lower pole piece 94, proximal coil 112 has a total of
four windings in the form of wire that has been wrapped around the
bobbin 152 in directly overlapping non-staggered single pitched
relationship.
[0079] When looking at the upper bobbin portion 150 surrounding the
pole piece 92 it can be seen that the wire of the distal coil 110
has been wrapped with a total of five windings. The first four are
even and one pitch wrapped on each other. The last winding
comprises a winding in one direction that is spaced, and a return
in the other direction as a filling winding. The final windings are
staggered so that there is a three pitch, or skip of windings which
are then filled in between with one winding in the spaces which
could also be two windings. The breadth as taken in the dimension
of B shown in FIG. 5 and in the other figures can be increased for
purposes of greater numbers of windings while at the same time
allowing a termination toward the rear of the pole pieces. Also,
coils 110 and 112 could have staggered windings for both sets of
coils to decrease relative width while taking advantage through
increasing the breadth of each coil.
[0080] The totality of windings is such where there are four on the
proximal coils 112 and 116 and five on the distal coils 110 and 114
unless all are staggered. This is true even though the distal coils
110 and 114 have been wound in each longitudinal direction after
the first four windings. In the three pitch configuration only
every third winding of the fifth winding is wound with a gap of two
spaces therebetween. The breadth B of the proximal windings 112 and
116 is only four exact windings while the distal windings 110 and
114 comprise a total of five windings.
[0081] Looking more specifically at FIG. 5A, it can be seen that an
alternative winding configuration is shown. In this particular
instance, the winding configuration shows the fact that windings
have been wound into a helix in the distal coil 110C. Coil 110C has
been wound so that at the termination of each winding such as at
point T, the wire returns by way of a wire return running along the
upper portion of the width in the form of wire running along the
width of the outer breadth portion.
[0082] The return wire is shown as wire 500. The wire is returned
and the second winding takes place along the width of the outer
breadth as winding 502. Winding 502 then terminates at T2 and
returns in the form of wire 503. The next windings on top of wire
503 are generally shown as windings 504. This process continues
depending upon the number of helixes to be wound.
[0083] In this manner, the breadth can be increased with return of
the wires 500 and 503. Here again, on the bottom portion, the
windings are formed in relative tangential arcuate contact with the
respective winding along the width so that a compactness of
windings 506 takes place providing for multiple windings in a
compact helical relationship. As a consequence, the return wires
500 and 503 can be returned in any particular manner along the
outer breadth of coil 110C and across the width thereby building up
the outer portion but not the inner portion between the respective
coils.
[0084] Looking more specifically at FIGS. 6 through 14, it can be
seen how the winding process takes place. The winding process has
been shown with relative movement of the bobbins and frame assembly
88 or 90. For purposes of convention, the bobbin and frame assembly
88 will be described in the winding process.
[0085] The ends of the pole pieces 92 and 94 are shown extending
through the plastic bobbin portion that is split and in part covers
the metal pole pieces.
[0086] The winding takes place on the bobbin members 150 and 152 of
the frame and bobbin 88 which will be described specifically as the
bobbins 93 and 95 respectively with regard to the pole pieces 92
and 94.
[0087] Each bobbin respectively 93 and 95 has a flange, disk, or
terminal wall that surrounds it toward the end proximate the
extension of the pole pieces 92 and 94. These are seen in the form
of the end flanges 97 and 99 as they pertain to the respective
bobbins 93 and 95.
[0088] At the other end of the bobbins 93 and 95 are stop positions
created by the frame and bobbin 88 terminating at flanges or
ledges. These are seen as terminal points, flanges, ledges, or stop
points respectively 101 for bobbin 93 and 103 for bobbin 95.
[0089] In order to wind the wire on the respective bobbins 93 and
95, relative motion is imparted to the frame and bobbin member 88
as it rotates around a needle 180. Needle 180 receives a supply of
wire 182 at its end 184. The wire supply from its end 184 can come
from any source. The rotational movement of the bobbin and frame
member 88 is in the direction of arrow 186. In order to feed the
wire 182 onto the bobbins 93 and 95 during winding, the bobbin and
frame member 88 moves in the direction of arrow 188.
[0090] The foregoing causes the winding of the wire 182 through the
relative motion in the direction of arrows 186 and 188 to extend
between the flange or step 103 and the bobbin flange 99. The
winding of wire 182 extends to its initial winding portion from the
terminal connector 132 and is wrapped initially from the flange
extension or ledge 103. The winding is formed with four successive
layers. The successive layers can be of any other number so long as
the relative degree of compaction is maintained as to the width W
and breadth B. Also, the last winding should terminate toward the
rear of the bobbins at stop points or ledges 101 and 103.
[0091] As seen in FIG. 7, the wire 182 has extended out to the
fourth or final winding that has been built up as shown by the
dotted lines on the bobbin portion 95. Here again, it can be seen
that the rotational movement is in the direction of arrow 186.
However, the in and out movement is shown as a relative movement in
the direction of arrow 190. This causes the movement of the frame
member or bobbin 88 to move in the reverse direction of arrow 188
so that the winding is paid up finally against the ledge 103. In
effect, the in and out relative movement in the direction of arrows
188 and 190 causes the feed to traverse the bobbins 93 and 95 as
rotation takes place.
[0092] In this particular case, the winding has included four wraps
with no spacing between them, in single pitch orientation. The
overlay of the wraps of the wire 182 are such that they make a
continuous wrap in a smooth and consistent manner for flush
relationship generally within the bounds of the ledge 103 and
terminal flange, disc or stop 99.
[0093] Here again, it should be understood that relative rotational
movement of the needle 180 can take place around the bobbin 95 or
as in this case the bobbin moved in the direction of arrow 186 for
wrapping purposes. It has been found preferable as to the feed of
the wire, to avoid less twist, that the bobbins 93 and 95 should be
rotated around the needle 180.
[0094] Looking more particularly at FIG. 8 after the bobbin 93 has
been wound, it can be seen that the needle 180 has moved to within
the space between the bobbins 93 and 95. At this point, the bobbin
95 around the pole piece 94 is then rotated in the direction of
arrow 202 in order to wrap the wire 182 being paid out from the
needle 180. As it wraps around the bobbin 95, it traverses a
totality of four wraps as shown in FIG. 8 in the direction of arrow
202.
[0095] In the particular showing of FIG. 8, arrow 204 indicates
movement or transversal of the frame and bobbin member 88 in order
to wrap the wire 182 on the winding course after it has been
conveyed from the end of bobbin 93. It should be borne in mind that
the wire 182 should be continuous between the respective
connections 130 and 132. It should also be noted that the wire 182
when extending from the bobbin 93 as coil 112 extends from the last
of the winding on bobbin 93. This extension can be seen as
extension 212 of the wire extending from the end of the winding on
bobbin 93.
[0096] As the frame and bobbin 88 rotationally turn around in the
direction of arrow 202, the movement of the bobbin 95 inwardly and
outwardly can be seen in the reciprocal manner as the frame and
bobbin member 88 moves in the direction of arrow 216. This movement
in the direction of arrow 216 provides for the final continuous
four layer wrap of single pitched wrap without any gaps or spaces.
After the wire 82 has been wrapped down to the base or terminal
ledge 103, it is then wrapped with a fifth wrap as seen in FIG. 10
with a three pitch configuration having a gap of two wire spaces
between the wrapped wire 182. This particular winding shown in FIG.
10 is the next to last winding or wrap of the fifth complete
winding and proceeds as shown in FIG. 11 to the end of the bobbin
95 at the flange, disc, or ledge 99.
[0097] At this point, as seen in FIG. 12, the final portion of the
fifth winding takes place by filling the respective gaps or spaces
created by the three pitch initial winding of FIG. 11. These double
gaps or spaces of the three pitch initial winding are filled. At
the side across the width W removed or remote from the proximal
coil 112 of the winding 110, there is a crossover. This crossover
is implemented across the removed width portion by relative
longitudinal movement.
[0098] As shown in FIG. 12 the needle 180 in relationship to the
bobbin and frame member 88 translates or crosses over a particular
initial winding at the width of the coil. This extension is across
the width of the coil as seen in FIG. 13. The winding of the wire
182 is thereafter laid down in the respective double wire gaps
between the three pitched wire as wound in FIG. 11.
[0099] As seen in FIG. 13, which shows the breadth B dimension of
the distal coil 110, the crossover takes place at the removed or
most distal width so as to not interfere within the interfacing gap
between the respective coils 110 and 112. This allows for the
needle 180 to pass therebetween freely and provide for the relative
translation as seen in the direction of the arrows of FIG. 13.
[0100] Thus, the crossover windings as seen in FIGS. 13 and 14 have
been laid at an advantageous area to not interfere within the
interfacing gap between the coils 110 and 112. Bobbins 93 and 95
have a wrap of wire 182 around them forming coils 110 and 112.
Bobbin 93 has four wraps while bobbin 95 has the equivalent of a
total of five single pitched wraps by the final reverse wrap
filling in the three pitched wrap. In summation, the last wrap of
the distal coil is formed by a three pitched or spaced wrap
traversing in one direction, and a wire filling wrap traversing in
the other direction. The majority is filled, but not one hundred
percent (100%) i.e. 4+1/3+1/3 equals 42/3. If a double or two pitch
wrap is used with a single space between each wrap before filling,
the final filling can be a single wire between the two pitches
completely filling the single space with a final wrap. Thus, the
one hundred percent (100%) double pitch provides 4+1/2+1/2 windings
making a total of five (5). This is shown in FIG. 15.
[0101] The winding as shown in FIG. 11 that initiates in FIG. 10
allows for the wire to terminate at the end of the bobbin 95 so
that it can then be wrapped around terminal 130. Terminal 130
receives the terminal end of the winding and allows it to be
secured thereon after the last winding or filling of the pitched
wrap of the coil 110 has taken place. This final winding is fed
down to the terminal 130 through a groove 135 that is on the same
side as groove 134. This can be seen in FIG. 4 where the groove
extends along the base of the frame and bobbin member 88.
[0102] As shown in the Figures, it can be seen that in the Figure
descriptions 1 through 14, a next to last three pitch traversal or
three wire winding has been undertaken for the distal coils 110 and
114 in order to provide for the double gaps or spaces in
between.
[0103] FIG. 15 shows a differently pitched orientation. As can be
seen in greater detail the respective coils analogous to coils 110
and 114 have been wound with a double pitch rather than a three
pitch next to last winding. The double pitch is such where a gap of
one wire is between each respective doubled pitched wire. In all
other respects, the configuration is the same.
[0104] Thus, as can be appreciated other multi-pitched
configurations can be oriented such as two and four pitched coils
as deemed by the total number of turns required and the
manufacturability. For purposes of explanation, the alternative
embodiment of the coils 110A through 116A are analogous to coils
110 through 116 as shown.
[0105] In addition to the showing of the hammerbank analogous to
that showing of FIG. 3, a lug 279 has been shown supporting the
hammerbank which serves to oscillate and drive the hammerbank in a
reciprocating manner. Thus, the only difference in the respective
showings of the double tiered or double line of hammers using coils
110A through 116A is the fact that the coils have been wound
insofar as the distal coils 110A and 114A are concerned with a
double pitch rather than a three pitch winding for the next to last
traversal prior to filling. The double pitch has then been filled
in with respect to an additional wire filled in with the
appropriate crossovers for the windings skipping only two wires
instead of three wires.
[0106] Other winding configurations can be utilized such that other
multiple pitches can be wound. In doing so, the wire 182 should
always return as to the last winding at the terminal point or the
ledge 101 so that the wire can then be terminated back to the
connection 132.
[0107] The three pitch winding can be seen graphically in FIG. 4
wherein the crossovers are shown on the distal coils 110 and 114.
The double windings are seated between the three pitched single
windings. The totality makes up the fifth complete winding. Other
winding relationships can be used with odd windings formed as the
third, seventh, ninth, eleventh, etc. complete winding wound on
second, sixth, eighth, and tenth windings. The principal is to have
the last winding for compaction purposes formed of two traversals,
one having spaced pitches, and the other filling in the spaces.
[0108] FIG. 16 shows the start of an alternative wrapping system
for the wire 182. In particular, the bobbin and frame assembly 88
has the terminals 130 and 132 as previously described. However, in
order to accommodate a different wrapping scheme to provide for
appropriate space between the proximal and distal coils, the
wrapping procedure of FIGS. 16 through 22 is utilized. The
fundamental concept in these figures is that a winding of the
distal coils which can also be applicable to the proximal coils
takes place by a first winding extending outwardly toward the
terminal points of the pole pieces 92 and 94 and then returns on a
longitudinal return LR.
[0109] The winding is effected by turning the frame and bobbin 88
around a needle 180 having the wire 182 extending therefrom.
However, the reverse and relative motion in the other direction can
also take place.
[0110] In FIG. 16 it is shown that the distal bobbin 93 for the
coil has a base flange portion 600. The base flange portion 600 has
an angular slot 602. The angular slot 602 can be in any particular
configuration so long as it allows access of the wire 182 from the
terminal 132 to be wrapped around the bobbin 93 forming the base
upon which the distal coil is wound. In this particular case, the
coil is wrapped in a clockwise direction around the bobbin 93
extending toward the end flange or stop 97A. 97A is analogous to
the flange or stop 97 in the previous embodiment. In like manner,
flange 99A is analogous to the flange or stop 99 in the previous
embodiment.
[0111] As the relative movement of the bobbin 93 turns, it wraps
the wire 182 around the bobbin in a clockwise wind until it
terminates at the end flange or stop 97A. The end flange or stop
97A has a slot 604 therein. The slot 604 is at an angle and allows
for the wire 182 to extend outwardly as shown in FIG. 17 in the
direction of the pole piece end 92.
[0112] The wire 182 as seen in FIG. 18 then passes through a slot
606 of the end flange 97A and traverses backwardly in the direction
of longitudinal return LR 1. When returning in the longitudinal
direction as longitudinal return LR 1, it travels along the outside
periphery of the winding shown in FIG. 17 on the removed portion of
the distal coil away from the space between the two respective
bobbin portions 93 and 95. In this way, the dimension on the
outside of the distal coil is extended without packing wire
internally into the space between the respective bobbins with their
windings 93 and 95.
[0113] When the longitudinal return LR 1 passes backwardly to the
flange or base 600, it then passes through a space 610 which allows
it to then traverse behind the flange in the direction of arrow 614
and then through the slot 602 to be a second winding. This second
winding continues in the same manner as the first winding moving
outwardly toward the flange or stop 97A. This can be seen as the
second winding of FIG. 19 which is being wound in the clockwise
direction of arrow 616.
[0114] This second winding extends in a clockwise wind again toward
end flange or stop 97A as seen in FIG. 20 after it has been wound
in the clockwise direction in FIG. 19. The second winding when it
traverses the interior portion between the two coils and bobbins
97A and 99A wraps around the existing winds and the longitudinal
return LR 1. Thus, the thickness or breadth B of the wrap is
increased in the area removed from the proximal coil wrapped around
bobbin 95 and is wrapped around bobbin 95 in a manner to increase
the wind at the exterior portion removed from the space between the
two.
[0115] The foregoing winding as can be seen with the winding
terminating at the end portion or flange 97A is then returned in
the direction of longitudinal return LR 2 as seen in FIG. 20. The
longitudinal return of LR 2 returns through the end flange 97A that
has a slot 626 therein so that the longitudinal return LR 2 can
extend backwardly in the area outside of the space between the two
bobbins 93 and 95. It then terminates within a second slot 628 of
the end flange or base flange 600.
[0116] A plurality of windings around the bobbin 93 with the
longitudinal returns LR 1 and LR 2 can be increased to extend the
number of longitudinal return wraps passing through the respective
slots 606, 610, 626, and 628. This creates a multiple number of
windings extending from the base flange 600 out to end 97A and
making a number of longitudinal returns that can be one, two, or
any number depending upon manufacturing capability.
[0117] Also, it can be understood that the longitudinal returns LR
1 and LR 2 can traverse along the longitude of the pole piece 92
after the pole piece has been wound in a normal manner with a
winding extending outwardly then backwardly in a uniform manner
without the longitudinal return. The inventive concept is to
increase the number of winds without decreasing the space between
the bobbins 93 and 95. Thus, any combination of longitudinal
returns or crossovers can be utilized to increase the breadth at a
dimension removed from the space between the respective pole pieces
92 and 94. Also, combinations of the longitudinal return wires LR 1
and LR 2 can also be utilized with crossovers as in the previous
embodiment.
[0118] After the longitudinal returns LR 1 and LR 2 are effected in
the final wraps, the wire 182 is then wound on the bobbin 95 in a
counter clockwise manner in the direction of arrow 640. This can be
seen clearly in FIG. 21 wherein the wire extends from the first
winding to the bobbin 95 and is then wrapped in a counter clockwise
direction. At the end of the windings, the wire is then returned
through a slot 646 in a slot analogous to the slots 134 as seen by
slot or groove 134A in FIGS. 18 and 20 in the side of the bobbin 88
of FIG. 4 so that they can then be terminated on terminal 130.
[0119] Further to this extent any combination of slots or windings
can take place at the ends of the respective bobbins 93 and 95 such
that terminal flange 97A and 99A can provide for returns in
different configurations. Also, the slots such as slots 610 and 628
can be such where they accommodate more than one longitudinal
return LR of a wire and can be also multiple in number. Thus, any
combination of returns can be utilized.
[0120] Any variation can be utilized to incorporate the pitch of
the width crossovers and the respective breadth. The net result
should be the ability to provide for a compact coil relationship to
allow such a winding by an analogous instrument as the needle 180
proceeding between the distal and proximal coils. The essence
fundamentally is to create a lesser incursion by the coils into the
area between the distal and the proximal coils as well as
minimizing the width between them for compact relationship of the
plurality of coils in a hammerbank along a particular bank. Thus,
this invention helps to limit the width as well as placing the
breadth of the coils in an orientation to maximize the winding
capability hereof.
* * * * *